Noise reduced PWM driver

ABSTRACT

A PWM driver for driving an electric device by a PWM signal includes an ECU that provides a command signal, first circuit that provides a carrier signal of a triangular shape having a preset frequency, a second circuit that forms a PWM signal having a duty ratio formed based on the carrier signal and the command signal and an output circuit that drives an output device. The second circuit includes a duty ratio limiting circuit that limits the duty ratio of the PWM signal to a range between a first duty ratio and a second duty ratio to prevent the wave shape of the PWM signal from becoming a shape of an impulse.

CROSS REFERENCE TO RELATED APPLICATION

The present application is based on and claims priority from Japanese Patent Application 2007-52747, filed Mar. 2, 2007, the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a PWM driver that switches an electric device on or off according to a PWM (pulse width modulation) signal.

2. Description of the Related Art

A PWM driver for controlling an electric device such as a motor or an electric heater sometimes encounters radio noises caused by high-frequency noises generated during PWM operation of the electric device. For example, a passenger of a vehicle may have a noise problem when the passenger is hearing music or some other program on a car audio set.

In order to solve this problem, JP-A-2005-185053 proposes to form the pulse shape of the PWM signal into a trapezoid whose rising and falling portions are controlled by the duty ratio thereof. JP-A-2006-187173 proposes to change the cycle of a carrier signal according to a preset pattern or randomly. The above proposals aim to prevent the frequency spectrum of high-frequency noises from concentrating at the same frequency band.

However, more high-frequency noises are generated where the duty ratio of the PWM signal is lower than a lower threshold value or higher than a higher than a higher threshold value, as shown in FIG. 5.

It has been found that this is caused because the carrier signal is shaped into an impulse where the on-duty of the PWM signal is lower than a lower threshold value as shown in FIG. 4B, or the on-duty of the PWM signal is higher than a higher threshold value as shown in FIG. 4C.

In this case, the above-described PWM drivers can not reduce these high frequency noises.

SUMMARY OF THE INVENTION

Therefore, an object of the invention is to provide an improved PWM driver that can effectively reduce high-frequency noise generated during PWM switching control.

According to a feature of the invention, a PWM driver for driving an electric device by a PWM signal includes input means for providing a command signal, first means for providing a carrier signal of a triangular shape having a preset frequency, second means for forming a PWM signal having a duty ratio formed based on the carrier signal and the command signal and output means for driving an output device, wherein the second means includes duty ratio limiting means for limiting the duty ratio of the PWM signal to a range between a first duty ratio Dα and a second duty ratio Dβ to prevent the wave shape of the PWM signal from becoming a shape of an impulse.

Therefore, radio noises caused during PWM control operation are suppressed or reduced, thereby solving the above-stated problem.

In addition to the above features, the following features are also provided: assuming that the carrier signal of the PWM signal has a cycle T1, a rising time Tr, a falling time Tf and a conducting period T2, the first duty ratio Dα is not smaller than (Tr+Tf)/T1; and the second duty ratios Dβ is not larger than 100−(Tr+Tf)/T1; the second means forms a PWM signal having 100% duty ratio when the command signal becomes higher than a level that corresponds to the second duty ratio Dβ; the output device is an electric heater.

According to another feature of the invention, a method of driving an output device by PWM-controlled electric power includes setting a lower limit duty ratio Dα of the PWM-controlled electric power and an upper limit duty ratio Dβ of the PWM-controlled electric power and

-   -   supplying the PWM-controlled electric power to the output device         if the duty ratio is between the lower limit duty ratio Dα and         the upper limit duty ratio Dβ.

In addition to the above features, the following features are also provided: assuming that the PWM-controlled electric power has a cycle T1, a rising time Tr, a falling time Tf and a conducting period T2, the lower limit duty ratio Dα is not smaller than (Tr+Tf)/T1; and the upper limit duty ratios Dβ is not larger than 100−(Tr+Tf)/T1.

It is also desirable to add the following features to the above features: cutting supply of the PWM-controlled electric power if the duty ratio becomes lower than the lower limit duty ratio Dα; and supplying the PWM-controlled electric power having 100% duty ratio if the duty ratio becomes higher than the upper limit duty ratio Dβ.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features and characteristics of the present invention as well as the functions of related parts of the present invention will become clear from a study of the following detailed description, the appended claims and the drawings. In the drawings:

FIG. 1 is a block diagram illustrating a PWM driver according to a preferred embodiment of the invention;

FIG. 2 is a circuit diagram of a control circuit of the PWM driver;

FIG. 3 is a graph showing an operation of PWM driver;

FIGS. 4A, 4B and 4C are graphs showing wave shapes of the PWM signal when the duty ratio of the PWM signal changes; and

FIG. 5 is a graph showing a relation between duty ratios of a PWM signal and high frequency noise levels contained in AM band (between 510 kHz and 1710 kHz) and LW band (between 150 kHz and 280 kHz).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A PWM driver according to a preferred embodiment of the present invention will be described with reference to the appended drawings.

The PWM driver is to be employed to control a PTC (positive temperature coefficient) heater of a vehicle air condition system.

As shown in FIG. 1, the air condition system includes an ECU (electronic control unit) 1, a battery 2, a first fuse 3, a PWM driver 4, a key switch 5, a second fuse 6, a PTC heater 8, etc. The ECU 1 is powered by the battery 2 via the first fuse 3 and the key switch 5. The PWM driver 4 is also powered by the battery 2 via the first fuse 3 and the key switch 5. The PWM driver 4 includes a P-channel MOSFET 7, an input signal processor 9 and a driver control circuit 10. The MOSFET 7 and the PTC heater 8 are connected in series to be separately powered by the battery 2 via the second fuse 6. The ECU 1 provides the PWM driver 4 with a digital command signal when a user operates the air condition system. The input signal processor 9 converts the digital command signal into an analog signal, which is sent to the driver control circuit 10.

As shown in FIG. 2, the driver control circuit 10 includes a buffer 11, a battery-side comparator 12, a ground-side comparator 13, resistors 14, 15, a pair of transistors 16, 17 connected in a totem-pole-series-connection and a final-stage comparator 18.

The input terminal IN of the driver control circuit 10 is connected with the input terminal of the buffer 11, an non-inverting terminals (+) of the comparators 12, 13 via the respective resistors 14, 15. The pair of series-connected transistors 16, 17 is connected between a voltage source VC and a ground. The junction of the transistors 16, 17 is connected with the output terminal of the buffer 11. The output terminal of the comparators 12, 13 are respectively connected with the bases of the transistors 16, 17. The output terminal of the buffer 11 is also connected with the inverting terminal of the final-stage comparator 18. The comparator 18 has a non-inverting terminal (+) connected with a triangular carrier wave generator 19 that provides a triangular wave signal of 100 Hz. Therefore, the comparator 18 provides a PWM signal whose level becomes high when the triangular wave signal is higher than the output signal of the buffer 11 and becomes low when the triangular wave signal is not higher than the output signal of the buffer 11. The MOSFET 7 turns on when the level of the PWM signal becomes low.

A threshold voltage α is applied to the non-inverting terminal of the ground-side comparator 13, and a threshold voltage β is applied to the inverting terminal of the battery-side comparator 12.

Therefore, if the input signal of the buffer 11 is lower than the threshold voltage α, the output signal of the ground-side comparator 13 becomes high, so that the transistor 17 turns on to connect the inverting terminal of the final-stage comparator 18 with the ground. If, on the other hand, the input signal of the buffer 11 is higher than the threshold voltage β, the output signal of the battery-side comparator 12 becomes high, so that the transistor 16 turns on to connect the non-inverting terminal of the final-stage comparator 18 with the voltage source VC. That is, if the input signal of the buffer 11 is lower than the threshold voltage β and higher than the threshold level α, the output signals of both the comparators 12 become low. Accordingly, both the transistors 16, 17 turn off, so that the final-stage comparator 18 provides the PWM signal, as shown in FIG. 4A.

As a result, the PTC heater 8 is PWM-controlled in a range between a first duty ratio Dα that corresponds to the threshold voltage α and a second duty ratio Dβ that corresponds to the threshold voltage β, as shown in FIG. 3.

On the other hand, the PTC heater 8 is fully turned off when the duty ratio of the PWM signal becomes smaller than the first duty ratio Dα, and fully turned on when the duty ratio of the PWM signal becomes larger than the second duty ratio Dβ, as shown in FIG. 3.

The PWM signal has a cycle T1, a rising time Tr, a falling time Tf and a conducting period T2, as shown in FIG. 4A.

The duty ratio D of the PWM signal is expressed as follows: D=T2/T1. The PWM signal having the first and second duty ratios Dα, Dβ are respectively set according to FIGS. 4B and 4C. For example, the first and second duty ratios Dα, Dβ thereof are respectively set as follows.

Dα=(Tr+Tf)/T1   (1)

Dβ=100−(Tr+Tf)/T1   (2)

Thus, the wave shape of the PWM signal can be prevented from becoming a shape of an impulse, so that high frequency noises can be prevented.

As a result, the driver or passenger can enjoy music or some other programs on a audio set without radio noises even when the PTC heater 8 is being operated.

However, the first and second duty ratios can be set to other ratios, such as 10% and 90%, as far as the wave shape of the PWM signal can be prevented from becoming a shape of an impulse.

Since the duty ratio of the PWM signal is set to 100% when the duty ratio is higher than a preset level, the full capacity of the PTC heater 8 can be utilized. In this case, a relay may be connected in parallel with the FET 7. It is also possible to fully turn off the PTC heater 8 if the duty ratio of the PWM signal becomes larger than the second threshold Dβ.

The MOSFET 7 may be replaced by a IGBT (insulated gate bipolar transistor) or the like.

In the foregoing description of the present invention, the invention has been disclosed with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made to the specific embodiments of the present invention without departing from the scope of the invention as set forth in the appended claims. Accordingly, the description of the present invention is to be regarded in an illustrative, rather than a restrictive, sense. 

1. A PWM driver for driving an electric device by a PWM signal, the PWM driver comprising: input means for providing a command signal; first means for providing a carrier signal of a triangular shape having a preset frequency: second means for forming a PWM signal having a duty ratio formed based on the carrier signal and the command signal; and output means for driving an output device, wherein the second means comprises duty ratio limiting means for limiting the duty ratio of the PWM signal to a range between a first duty ratio Dα and a second duty ratio Dβ to prevent the wave shape of the PWM signal from becoming a shape of an impulse.
 2. A PWM driver as in claim 1, wherein: assuming that the PWM signal has a cycle T1, a rising time Tr, a falling time Tf and a conducting period T2, the first duty ratio Dα is (Tr+Tf)/T1; and the second duty ratios Dβ is 100−(Tr+Tf)/T1.
 3. A PWM driver as in claim 1, wherein the second means forms a PWM signal having 100% duty ratio when the command signal becomes higher than a level that corresponds to the second duty ratio Dβ.
 4. A PWM driver as in claim 1, wherein the output device is an electric heater.
 5. A method of driving an output device by PWM-controlled electric power comprising: setting a lower limit duty ratio Dα of the PWM-controlled electric power and an upper limit duty ratio Dβ of the PWM-controlled electric power; and supplying the PWM-controlled electric power to the output device if the duty ratio is between the lower limit duty ratio Dα and the upper limit duty ratio Dβ.
 6. A method as in claim 5, wherein: assuming that the PWM-controlled electric power has a cycle T1, a rising time Tr, a falling time Tf and a conducting period T2, the lower limit duty ratio Dα is (Tr+Tf)/T1; and the upper limit duty ratios Dβ is 100−(Tr+Tf)/T1.
 7. A method as in claim 5, further comprising: cutting supply of the PWM-controlled electric power if the duty ratio becomes lower than the lower limit duty ratio Dα; and supplying the PWM-controlled electric power having 100% duty ratio if the duty ratio becomes higher than the upper limit duty ratio Dα.
 8. A method as in claim 7, wherein the output device is an electric heater. 